1. Introduction to Armadura® Material Science

Armadura metal roofing is engineered using one of the most durable and widely studied materials in the metal roofing industry: G90 galvanized steel. This material is the foundation of the Armadura® steel roofing system and is central to its long-term performance, corrosion resistance, structural rigidity, and winter durability in Canadian climates.

Understanding the full composition of G90 steel—including its zinc mass, metallurgical bonding, substrate properties, and coating behavior—is essential for understanding why Armadura metal roofing performs differently from other roofing systems. This encyclopedia entry provides a comprehensive examination of the G90 steel specification, its chemical structure, mechanical properties, coating durability, and the reasons it is selected for Canadian manufacturing.

2. What Is G90 Galvanized Steel?

G90 galvanized steel is a steel sheet coated with 90 grams of zinc per square meter, applied through a controlled hot-dip galvanization process. The designation “G90” is defined by the ASTM A653/A653M standard, which governs the performance and coating requirements for galvanized steel in North America.

2.1 Zinc Mass Specification

The “90” in G90 represents the total coating weight of 0.90 oz/ft² (approximately 275 g/m²), distributed evenly on both sides of the steel sheet.

This equates to:

137.5 g/m² per side, or
~1.2 mil (0.0012″) coating thickness per side

This zinc mass provides significantly stronger corrosion protection compared to lighter coatings like G40 (40 g/m² per side) or G60 (60 g/m² per side), which are commonly found in lower-cost imported roofing materials.

2.2 Why Zinc Coating Matters

Zinc serves two critical functions:

Barrier Protection
Creates a physical barrier between oxygen/moisture and the steel substrate.
Cathodic (Galvanic) Protection
Zinc corrodes sacrificially before the underlying steel, preventing rust penetration even when scratches, cuts, or cracks occur.

This is why Armadura’s G90 steel roofing maintains corrosion resistance even decades after installation.

3. The Metallurgical Bond Between Zinc and Steel

The G90 galvanization process occurs through a molten zinc bath, which forms a metallurgical bond between the coating and the steel substrate. This bond consists of a layered structure:

Gamma layer (Γ) — iron-zinc alloy
Delta layer (δ) — transitional alloy zone
Zeta layer (ζ) — crystalline zinc-iron alloy
Eta layer (η) — pure outer zinc coating

3.1 Benefits of Metallurgical Bonding

This multi-layer system improves:

Surface adhesion for coatings such as SMP
Corrosion resistance
Structural uniformity
Resistance to peeling or flaking
Scratch durability

The metallurgical bond also ensures that G90 steel maintains its protective qualities even when the outer surface shows wear over decades.

4. Why Armadura® Uses G90 Instead of G60 or G40 Steel

Many imported or lower-cost metal roofing systems use thinner zinc coatings such as G40 or G60. While these meet minimum standards, they do not provide adequate long-term corrosion resistance in Canadian environments.

Performance Differences in Real-World Exposure

Coating Grade	Zinc Mass	Lifespan in Canadian Climate	Notes
G40	Very thin	10–15 years	Very poor for winter, moisture, and salt exposure
G60	Moderate	20–30 years	Better, but insufficient for long-term roofing
G90	Heavy	40–70 years	Ideal for Canadian climates; standard for Armadura roofing

Armadura’s commitment to long-term durability is one of the primary reasons its panels are manufactured with full G90 zinc mass, rather than the thinner coatings found in many competing systems.

5. Chemical Composition of G90 Steel (Substrate Level)

The substrate steel beneath the galvanization layer typically consists of:

Iron (Fe): 98–99%
Carbon (C): <0.2%
Manganese (Mn): 0.20–0.80%
Phosphorus (P): <0.04%
Sulfur (S): <0.05%

This low-carbon formulation improves ductility and formability—critical when stamping Armadura’s interlocking steel shingle profiles.

5.1 Why Low Carbon Steel is Used

Low-carbon steel provides the ideal balance of:

Strength
Flexibility
Resistance to cracking during stamping
Stable expansion/contraction behavior

This is especially important for Canada’s freeze–thaw conditions and temperature swings.

6. Mechanical Properties of G90 Steel in Armadura® Metal Roofing

The mechanical behavior of G90 galvanized steel plays a major role in the performance of Armadura metal roofing under snow load, thermal expansion, wind uplift, and installation stress. While the zinc coating provides corrosion protection, it is the steel core that delivers strength and structural rigidity.

The key mechanical properties include:

6.1 Yield Strength

Typical G90 sheet steel used in roofing has a yield strength between:

33,000–50,000 psi (230–345 MPa)

This determines how much force is required before the metal begins to deform permanently.
Armadura’s steel shingles are stamped into shape without cracking because the steel is engineered for high formability + high strength.

6.2 Tensile Strength

G90 steel provides a tensile strength around:

45,000–65,000 psi (310–450 MPa)

This measures the maximum pulling force the metal can withstand before breaking.
It matters for:

Snow load pressure
Wind uplift forces
Weight distribution across interlocking panels

6.3 Elongation Percentage

Typical elongation values for roofing-grade G90 steel:

20–28%

This means the steel can stretch before breaking, which is essential during the stamping process used to form Armadura’s interlocking shingle geometry.

High elongation ensures:

No cracking of metal during shape formation
No micro-fracturing of zinc coating
Better long-term expansion/contraction behavior

6.4 Modulus of Elasticity

Steel’s modulus of elasticity (~200 GPa) determines how stiff the material is when bending forces are applied.

This is critical because Armadura roofing:

Supports snow load
Resists foot traffic better than softer aluminum
Retains shape under winter stress

7. Corrosion Behavior of G90 in Canadian Climate

Corrosion is one of the most significant long-term threats to metal roofing. The performance of Armadura steel roofing relies heavily on how the zinc coating interacts with Canadian environmental conditions.

7.1 Zinc Patina Formation

Zinc undergoes a natural aging process:

Fresh zinc reacts with oxygen → zinc oxide
Zinc oxide reacts with moisture → zinc hydroxide
Zinc hydroxide reacts with CO₂ → zinc carbonate
Zinc carbonate forms a stable patina layer

This patina layer:

Protects underlying zinc
Slows future corrosion
Self-heals minor scratches
Forms quickly in Canadian climates

This is why Armadura metal roofing maintains its coating integrity for decades.

7.2 Winter Corrosion Resistance

Canadian winters contain:

High humidity
Freeze–thaw cycles
Snow and ice accumulation
Road salt airborne particles in some regions

G90 steel is designed to withstand these forces without:

Red rust formation
Flaking
Pitting corrosion
Coating breakdown

Thinner coatings like G40 or G60 fail much sooner in these conditions.

8. Zinc Aging vs. Aluminum Oxidation (Armadura vs Aluminum Roofing)

Some metal roofing competitors use aluminum panels, which behave very differently.

8.1 Aluminum Oxidation

Aluminum forms:

Aluminum oxide (Al₂O₃)
Hard
Brittle
Easily cracked under deformation

This creates risks during:

Winter temperature swings
Hail impact
Fastener tightening
Panel expansion

8.2 G90 Zinc Aging (Armadura)

Zinc patina:

Flexible
Stable
Slow aging
Highly protective
Ideal for rough climate exposure

This is why Armadura steel roofing tends to outperform aluminum systems in Canadian climates.

9. G90 Steel Thickness in Armadura Roofing

G90 refers to the zinc coating weight, not the steel thickness.
However, Armadura uses structural-grade steel thickness optimized for:

Interlocking strength
Impact resistance
Winter load behavior
Fastener retention

Typical thickness ranges:

26–28 gauge for residential steel roofing (0.45–0.55 mm)

But the material feels more rigid because:

G90 thick zinc layer adds surface stiffness
Armadura’s pressed geometry increases strength
Interlocking design increases rigidity across the roof plane

10. Surface Coatings Applied on G90 Steel

After galvanization, Armadura metal roofing receives an SMP (Siliconized Modified Polyester) coating.

The coating process includes:

Chemical cleaning and pretreatment
Primer application
SMP crinkle finish topcoat
High-temperature curing

Why this matters:

SMP provides UV protection
Prevents chalking
Increases scratch resistance
Creates textured surface for better snow behavior
Maintains elasticity during winter contraction

This is the coating that gives Armadura its long-term color stability and Canadian climate durability.

11. Structural Behavior of G90 Steel in Armadura® Shingle Geometry

One of the most important advantages of Armadura metal roofing is how its G90 steel substrate behaves once it is pressed into the interlocking shingle profile. The geometry of the shingle dramatically increases stiffness and structural resistance far beyond what the raw sheet thickness would suggest.

11.1 Profile Engineering

Armadura steel shingles include:

Pressed ridges
Angular bends
Reinforced edges
Channel interlocks
Folded borders

These shape elements increase the moment of inertia, which directly increases resistance to bending and deformation.

11.2 Structural Strength Multiplication

A flat sheet of G90 steel might flex under load —
but when stamped into the Armadura profile:

Bending resistance increases 3–5×
Lateral stiffness increases significantly
Snow load distribution becomes uniform
Uplift resistance improves dramatically

This is why a relatively thin gauge steel can outperform much thicker flat panels.

12. The Armadura Interlock System and Its Material Requirements

The interlocking system that Armadura uses requires steel with:

High ductility (to avoid cracking during stamping)
Stable thermal expansion characteristics
Strong edge-retention under repeated freeze–thaw cycles
Good galvanic protection near the interlock edges

G90 steel meets these requirements perfectly.

12.1 Why G90 Is the Ideal Match for Interlocking Designs

Interlocking designs create areas of:

Pressure concentration
Metal folding
Tight contact between overlapping zones

A thin zinc coating (G40 or G60) cannot survive these mechanical stresses without:

Micro-cracking
Premature oxidation
Moisture penetration
Substrate exposure

G90’s thick coating provides adequate sacrificial mass to survive decades of mechanical cycling in the interlocks.

13. Panel Expansion and Contraction Calculations (Thermal Movement)

All metal roofs expand and contract due to temperature changes.
But Armadura steel roofing moves significantly less because of:

Low thermal expansion coefficient of steel
Small individual panel dimensions
Interlocking geometry limiting movement

13.1 Steel Thermal Expansion Formula

Steel expands at approx:

12 μm/m·°C

Example:
If a long metal sheet is 20 feet (6 meters) and experiences a 40°C temperature swing:

Expansion ≈ 12 × 6 × 40 = 2.88 mm of movement

This is why long panels shift, warp, or “oil-can.”

Armadura shingles solve this:

Armadura shingles are small.
Even with large temperature swings:

Expansion is typically:

0.2–0.4 mm per shingle

This is negligible.

Why this matters:

Fasteners remain stable
No deformation of long sheets
No thermal “popping” noises
Better winter performance
Reduced risk of coating stress

14. Armadura G90 Steel vs Imported Steel Roofing Products

Many imported metal roof systems use:

G40 or G60 steel
Unknown coating standards
Lower quality control
Thinner substrates
Weak adhesion coatings
Lower-grade galvanization processes

14.1 Problems with Imported Low-Grade Steel

Common failure points in cheaper metal roofing:

Edge rust
Surface chalking
Corrosion near cut lines
Coating delamination
Weak impact resistance
Rapid UV degradation

14.2 Advantages of Canadian G90 Steel

Armadura steel roofing:

Uses ASTM-certified G90 zinc
Follows Canadian manufacturing tolerances
Maintains consistent thickness
Has strict quality control during coating
Undergoes standardized adhesion testing

This ensures long-term reliability in Canadian climates.

15. Why Canadian Manufacturing Matters for Armadura®

The performance of Armadura steel roofing is directly tied to the consistency of its manufacturing processes.

Canadian production ensures:

Better climate calibration
Required snow load test standards
Material selection tuned for Canada
Proper metal tempering
SMP coating optimized for real Canadian UV exposure

Imported systems often fail because they are designed for:

Warmer climates
Lower snow loads
Lower humidity levels
Non–freeze–thaw regions

Armadura is engineered specifically for Northern conditions.

16. Zinc Layer Degradation Over Decades

G90 zinc does not stay at full thickness forever — it slowly degrades through natural oxidation.

Typical Zinc Erosion Rates

In Canadian conditions:

0.4–0.8 µm/year

Given zinc layer thickness (approx 20–25 µm):

Expected corrosion protection lasts:

30–55 years before substrate exposure

But with SMP coating and proper interlocks, total lifespan extends to:

50–70+ years

This is exactly why Armadura steel roofing outlasts:

Asphalt shingles (10–15 years)
Thin-coat metal roofing
Aluminum systems with brittle oxide layers

17. SMP Coating Chemistry on Armadura® G90 Steel

The SMP (Siliconized Modified Polyester) coating applied to Armadura metal roofing is a multilayer protective system designed to shield the G90 galvanized steel substrate from UV radiation, moisture, abrasion, and thermal cycling.

17.1 Composition of SMP Coatings

Typical SMP coatings used in Canadian manufacturing include:

Polyester resins for adhesion
Silicon additives for weather resistance
Pigments for color stability
Ceramic granules or micro-texture agents (crinkle finish)
UV inhibitors
Heat-resistant additives

This formulation provides a durable, flexible finish that outperforms older acrylic or polyester-only coatings.

17.2 Role of Silicon Additives

Silicon increases:

Surface hardness
UV reflectivity
Long-term color stability
Coating elasticity
Scratch resistance

SMP coatings maintain flexibility even at temperatures below –20°C, which is essential for Canadian roofing exposed to freeze–thaw cycles.

Benefits for Armadura steel roofing:

Reduced cracking
Lower chalking levels
Longer color retention
Greater surface durability

18. Adhesion Strength and Curing Process

Before the SMP topcoat is applied, G90 steel undergoes:

Surface cleaning
Chemical pretreatment
Primer coating
High-temperature oven curing

18.1 Why High-Temperature Curing Matters

Curing bonds the SMP coating directly into:

The zinc layer
The metallurgical alloy zone

This creates a single integrated surface layer rather than a simple film.

This improves:

Longevity
Impact resistance
Scratch durability
UV resistance
Coating adhesion

19. G90 Zinc Edge Protection (Cut-Edge Corrosion Resistance)

One of the greatest advantages of G90 galvanized steel is its cut-edge protection.

When a piece of Armadura steel roofing is cut:

The zinc coating near the cut is exposed
Zinc sacrificially corrodes before steel
The corrosion layer spreads outward, preventing rust

This is known as galvanic healing.

Why this matters:

Every Armadura steel shingle requires cutting near:

Eaves
Ridges
Valleys
Gables
Transitions

With G90 zinc mass:

Edges remain protected
Long-term corrosion is prevented
Substrate remains intact for decades

G40 or G60 coatings do NOT protect cut edges long-term.

20. G90 vs. Galvalume: Which Is Better for Canada?

Some metal roofing systems use Galvalume, an aluminum-zinc alloy coating.

20.1 Galvalume Composition:

55% aluminum
43.5% zinc
1.5% silicon

20.2 Advantages of Galvalume

Excellent corrosion resistance in dry climates
Strong heat reflectivity

20.3 Disadvantages in Canadian Climates

Aluminum layer becomes brittle in freezing conditions
Poor edge protection
Susceptible to cracking under thermal contraction
Can fail faster at panel cuts in wet climates
Weaker performance in snow load zones

Why Armadura uses G90 instead of Galvalume

G90 has better cut-edge performance
G90 outperforms under freeze–thaw stress
G90 has superior durability under constant winter moisture
G90 tolerates Canadian cold better
G90 supports interlock stamping without fracturing

21. SMP Coating and Long-Term Weather Resistance

The SMP coating on Armadura roofing protects against:

UV degradation
Snow abrasion
Ice adhesion
Moisture penetration
Airborne pollutants
Acid rain
Salt spray in urban areas

21.1 Color Stability

SMP coatings typically maintain:

High gloss retention
Low fade rates
Low chalking

Even after 20–30 years.

This is why Armadura roofing maintains a clean, crisp appearance decades into its lifespan.

22. How G90 and SMP Work Together

The combination of:

G90 zinc layer + SMP coating

creates a two-tiered defense system:

Tier 1 — SMP Coating (outer layer)

Protects against:

UV
Scratching
Weather abrasion
Temperature cycling
Color fading

Tier 2 — G90 Zinc (inner layer)

Protects against:

Corrosion
Moisture
Oxidation
Steel substrate exposure

Why the combination matters:

Most metal roofing failures begin when:

The coating fails
The zinc is too thin
Moisture reaches bare steel

Armadura prevents all three failure pathways.

23. Failure-Mode Resistance in Armadura® G90 Steel Roofing

A roofing system’s durability is defined not only by how it performs under normal conditions but by how it resists failure modes — the mechanisms by which roofing materials deteriorate over time.
Armadura metal roofing, through its G90 galvanized steel composition and SMP coating, provides resistance across all major roofing failure types.

Below is an engineering breakdown.

23.1 Moisture-Driven Failure (Water Absorption & Rust)

Asphalt

Absorbs moisture
Swells, cracks, and peels
Promotes rot in decking
Breaks down in freeze–thaw cycles

Armadura G90 Steel

Zero moisture absorption
Zinc prevents rust at cut edges
Coating prevents water contact with substrate
Freeze–thaw cycles do not penetrate material

Result: No structural moisture failure over decades.

23.2 UV & Solar Radiation Failure

Asphalt

UV breaks down petrochemical binders
Causes brittleness
Leads to granule loss

Armadura Steel Roofing

SMP coating reflects UV
Resists chalking and fading
Maintains elasticity under solar heating

Result: UV-resistant for 30–40+ years.

23.3 Thermal Movement Failure (Expansion/Contraction)

Large metal sheets expand significantly.

Standing Seam / Long Panels

Movement can be 2–5 mm per panel
Causes oil-canning
Warps fasteners or clips

Armadura Interlocking Shingles

Small shingles move ~0.2–0.4 mm
No oil canning
No thermal warping
Hidden fasteners remain secure

Result: Extremely stable under thermal cycling.

23.4 Impact Failure (Hail, Debris)

Asphalt

Loses granules
Bruises
Cracks

Aluminum Roofing

Dents easily
Low structural rigidity

Armadura G90 Steel

Hard surface resists penetration
High ductility absorbs impact
Stamped profile increases impact strength
Zinc coating protects exposed zones

Result: Strong impact resistance in severe weather.

23.5 Wind Uplift Failure

Asphalt Shingles

Vulnerable at edges
Adhesive strips weaken over time
Can lift or tear

Armadura Steel Roofing

Fully interlocked system
Hidden fasteners
Steel density resists uplift
Tested to Canadian wind zones

Result: Superior wind uplift resistance.

24. Long-Term Zinc Erosion Modeling (50–70+ years)

Corrosion scientists estimate zinc erosion under Canadian conditions at:

0.4–0.8 microns per year
depending on humidity, exposure, salt levels, and orientation.

G90 thickness per side:

15–20 microns

Expected protective lifespan:

25–40 years per side, or
50–70+ years total
before zinc is fully consumed at any exposed edge.

This matches the expected lifespan of Armadura steel roofing in real-world installations.

25. G90 Aging vs SMP Aging

SMP Coating (outer layer)

Ages slowly
Minimal chalking
UV-resistant
Protects G90 from premature erosion

G90 Zinc (inner layer)

Sacrificial protection
Slows oxidation
Remains effective even after minor scratches

Combined Effect

The SMP layer reduces zinc erosion significantly:

Less exposure to humidity
Less contact with air pollutants
Lower surface degradation rates

This extends roofing lifespan beyond that of G90 alone.

26. SMP Texture and Its Functional Benefits

The Armadura crinkle-texture SMP coating is not only aesthetic. It provides engineering benefits:

Traction Behavior

Increases friction
Prevents sudden snow slides

Surface Strength

More resistant to micro-abrasion
Better durability during installation

Coating Thickness Uniformity

Crinkle finish adds micro-ridges:

Increasing coating thickness
Improving scratch resistance
Adding texture for more uniform aging

This improves long-term performance under Canadian conditions.

27. Armadura G90 Steel and Winter Climate Performance

Key winter considerations:

Freeze–Thaw Cycles

G90 steel does not absorb moisture
SMP coating remains flexible
No cracking or delamination

Snow Load

Steel rigidity supports distributed snow weight
Stamped shingle geometry increases strength

Ice Damming

No water absorption
Zinc layer protects from moisture backflow

Wind Chill

No impact on steel substrate
No embrittlement under Canadian cold

Result: Best-in-class winter reliability.

28. G90 Steel and Summer Heat Performance

Heat Exposure in Canadian Summers:

Roof surfaces can exceed 70°C
Coating must resist thermal breakdown

SMP’s heat behavior:

Highly stable under thermal load
Prevents blistering
Maintains adhesion

Steel substrate behavior:

Low thermal expansion compared to aluminum
Stable attachment in high heat
Minimal movement under temperature cycling

Combined:
Armadura roofing performs predictably in extreme heat.

29. Comparative Material Tables for Roofing Science

Below are the definitive engineering comparisons showing why G90 galvanized steel, as used in Armadura metal roofing, is the optimal roofing substrate for Canadian climates.

Table 1 — Corrosion Protection Comparison

Material Type	Coating	Corrosion Resistance	Winter Performance	Edge Protection
Armadura G90 Steel	90 g/m² zinc	Excellent	Excellent	Strong
G60 Steel	60 g/m² zinc	Moderate	Fair	Weak
G40 Steel	40 g/m² zinc	Low	Poor	Very Weak
Galvalume (AZ55)	Aluminum-Zinc	High in dry climates	Moderate in cold	Low
Aluminum	Oxide Layer	Moderate	Brittle in winter	Poor

Table 2 — Structural Behavior Comparison

Property	Armadura G90 Steel	Aluminum Roofing	Asphalt Shingles
Rigidity	High	Low	Very Low
Dent Resistance	High	Very Low	N/A
Thermal Movement	Low	High	Medium
Moisture Absorption	0%	0%	High
Freeze–Thaw Tolerance	Excellent	Moderate	Very Poor

Table 3 — Coating Durability Comparison

Coating Type	UV Resistance	Chalk/Fade	Flexibility in Winter	Heat Durability
SMP Crinkle Finish (Armadura)	Excellent	Low	Excellent	Excellent
Standard Polyester	Moderate	Medium	Poor	Fair
PVDF (Kynar)	Excellent	Very Low	Moderate	Excellent
Acrylic	Low	High	Poor	Poor

30. Long-Term Aging Behavior of Armadura® G90 Steel

The combined aging curve of G90 zinc + SMP coating follows a predictable pattern:

Stage 1 — First 10 Years

Minimal color change
Zinc patina develops
Highest coating integrity
Zero substrate exposure

Stage 2 — 10 to 25 Years

Slight reduction in gloss
Minor SMP surface texturing
Zinc patina fully stabilized
Excellent winter resistance

Stage 3 — 25 to 45 Years

SMP begins low-level chalking (normal)
Zinc thickness reduced by ~25–40%
No red rust
No structural deterioration

Stage 4 — 45 to 70+ Years

Depending on environment, zinc may thin
Substrate may eventually begin shallow oxidation
Roofing system still structurally sound
Majority of roofs remain fully functional

This aligns with the real-world performance expectations of Armadura steel roofing in Canada:
50–70+ years of functional life.

31. Canadian Climate Advantage: Why G90 Is Superior in the North

Canada’s climate is one of the harshest in the world for roofing systems.

Key environmental hazards:

Snow load
Freeze–thaw cycles
High humidity
Ice formation
UV reflection off snow
Wind-driven rain
Sudden temperature swings

G90 steel + SMP coating withstands all of these due to:

Thick sacrificial coating
Stable expansion rates
High rigidity
Non-absorbent material structure
Superior interlock performance
Strong surface adhesion

32. Comprehensive Summary: Why Armadura® Uses G90 Steel

Armadura steel roofing is engineered using G90 galvanized steel because:

Structural Benefits

High rigidity
Excellent impact resistance
Stable thermal behavior

Corrosion Benefits

Thick zinc layer
Long-term substrate protection
Strong cut-edge performance

Coating Benefits

SMP offers UV resistance
Low fade rates
High winter flexibility

Climate Benefits

Handles Canadian winters
Performs in summer heat
Stable under freeze–thaw cycles

Longevity Benefits

50–70+ year lifespan
Predictable aging curve
Minimal long-term maintenance

Together, these properties create one of the most durable and climate-appropriate roofing materials available in North America.

33. Conclusion

The use of G90 galvanized steel in Armadura® metal roofing is not incidental — it is fundamental to the roofing system’s performance, engineering reliability, and long-term durability.
G90 provides:

Maximum corrosion resistance
Predictable aging
Superior interlock behavior
Exceptional winter durability
Better performance than aluminum and thin-coat steels
A proven 50–70 year service life

This deep technical advantage is one reason Armadura metal roofing has become one of Canada’s most engineered roofing systems for harsh climates and heavy snow regions.

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